Aluminum base alloys

ABSTRACT

Aluminum base alloys, having improved properties as regards mechanical working treatments, according to the invention are characterized by a content of 0.5 - 10.0 wt. % iron, without or with a very small content (up to 0.1 wt. %) of Li or Na or Sr or Ba. The alloy has a microstructure comprising a substantial portion of refined Al 3  Fe and/or very fine Al 6  Fe.

This is a continuation-in-part of our prior copending application Ser. No. 277,511, filed August 3, 1972, which is now abandoned.

This invention relates to aluminium base alloys, and one object is to provide aluminium-iron alloys possessing greatly improved properties over conventional alloys designed for mechanical working treatments.

Reference is made in the following description to the accompanying drawings FIGS. 1 to 8 wherein

FIG. 1 shows an Al-Fe equilibrium phase diagram

FIG. 2 illustrates the microstructure of an Al-3% Fe alloy showing the normal coarse Al₃ Fe needle shaped compounds present in the structure.

FIG. 3 is a proposed phase diagram showing the formation of the Al-Al₆ Fe eutectic.

FIG. 3(a) illustrates the microstructure of an Al-3% Fe alloy showing the refined form of the Al₆ Fe compound.

FIG. 4 shows the influence of temperature gradient G and growth rate R on the formation of the two types of eutectic structure in aluminium-iron alloys.

FIG. 5 illustrates the microstructure of an Al-3% Fe alloy containing lithium showing the refinement of the structure achieved.

FIG. 6 illustrates the microstructure of an Al-3% Fe alloy containing sodium showing the refinement of the structure achieved.

FIG. 7 illustrates the microstructure of an Al-3% Fe alloy containing strontium showing the refinement of the structure achieved.

FIG. 8 shows fully refined Al₆ Fe structure produced by rapid cooling of the alloy and subsequent cold working.

The aluminium-iron alloys as a class have not been developed commercially to any extent primarily due to the embrittling nature of the aluminium-iron compound formed in the alloy structure on solidification. FIG. 1 shows that the aluminium rich aluminium-iron alloys form a simple eutectic phase system similar to that of the aluminium-silicon alloys. Iron has only slight solid solubility in aluminium and forms a compound Al₃ Fe which undergoes a eutectic reaction at 1.7% Fe and 655° C. The microstructure normally present in aluminium-iron alloys at the slow and moderate rates of solidification encountered in practice, is one containing large particles or long interconnected plates of the Al₃ Fe compound. (See FIG. 2). The Al₃ Fe compound being hard and brittle, renders any alloys having such structures of low commercial value due to their inherently low ductility. Further, the large particles offer little dispersion hardening effect and the tensile strength of the alloys is only marginally above that of pure aluminium. The mechanical working of the alloys by rolling, forging, extrusion, etc. is impractical owing to the coarse nature of the aluminium - Al₃ Fe eutectic.

For the above reasons the aluminium-iron based alloys have not been commercially developed, and indeed it has hitherto been a general aim for most commercial aluminium alloys to have iron contents as low as possible.

It is one object of the invention to so refine the structures formed in aluminium rich aluminium-iron alloys as to render them suitable for commercial use in both cast and wrought forms. Refinement of the alloy structures greatly improves the mechanical properties, particularly the ductility, and enables the alloys to be subsequently shaped by conventional metal working processes. It is a further object of the invention to provide controlled and stable refinement of the structures formed on solidification of the alloys.

As well as the equilibrium phase, Al₃ Fe, formed in aluminium rich aluminium-iron alloys on solidification, an additional compound Al₆ Fe is formed under particular conditions of solidification and/or when specific alloy additions are made. This compound forms by a eutectic type reaction with aluminium at a eutectic composition of approximately 3.5% Fe, and at a eutectic temperature lower than the aluminium - Al₃ Fe eutectic temperature. FIG. 3 shows a proposed phase diagram for the formation of the Al-Al₆ Fe eutectic. This proposed phase diagram is based on results obtained in the course of the development of the alloys of this invention. The structure formed is very fine, the Al₆ Fe compound taking the form of short interconnected rods which appear cylindrical in section (see FIG. 3(a)), and the Al-Al₆ Fe eutectic constitutes 90% or more of the microstructure.

The compound Al₃ Fe can also be made to assume comparable structures under particular conditions of solidification in combination with special alloy additions. It is hence a further object of the invention to define the particular conditions of solidification and/or the alloy additions necessary to cause either the formation of the Al₆ Fe compound or the refinement of the Al₃ Fe compound, whereby to attain, in the microstructure at least 90% content of Al-Al₃ Fe eutectic in refined form, i.e. Al₃ Fe having a particle size not greater than 10 microns. By the expression "refined form" as used herein, with special reference to a form of Al₃ Fe, we mean having a particle size not greater than 10 microns.

We have found that the parameters needing to be varied to control the form of the two compounds are:

a. the temperature gradient existing between the solid and liquid metal during casting, commonly referred to as G, expressed in degrees C/millimeter;

b. the growth rate of the alloy phases as they solidify, commonly referred to as R, expressed in microns/second; and

c. the composition of the alloy, particularly with respect to trace alloying element additions.

Control of the temperature gradient G may be achieved by careful control of the temperature of the molten metal, the rate of pouring, the rate of cooling and the progress of solidification. One way in which such control can be effected is by use of a directional solidification furnace. As is well known, a furnace of this type is designed so that there is relative movement between a column of metal and the furnace cavity. Other important means for such control include the operation of a direct chill (D.C.) casting station in such a way as to produce the required temperature gradient. The value G is, in the present context, greater than 1° C./millimeter and may amount to several degrees C per millimeter.

The growth rate R also varies with the rate of heat extraction from the solidifying metal, a high rate of heat extraction yielding a high growth rate. For the formation of Al₃ Fe the growth rate (R) is within the range 1-500 microns per second, whilst the growth rate for formation of Al₆ Fe is at least 100 microns/second and preferably is greatly in excess of the latter value. The effect of the growth rate and temperature gradient on the formation of the two different compounds Al₃ Fe and Al₆ Fe can best be expressed and controlled by a diagram such as that shown in FIG. 4. A preferred structure containing the compound Al₆ Fe in binary alloys containing only aluminum and iron is obtained by exceeding the growth rate/temperature gradient parameters defined by the boundary line A--B in the diagram. In practice it has been found that the usual alloy impurities present in aluminum do not markedly influence the position of the transition boundary between the two types of structures. As the Al-Al₆ Fe eutectic structure has a characteristic form that results in markedly improved mechanical properties of the alloy, due to the refined or modified nature of the structure, it is a preferred feature of the invention to produce such a structure by selection of casting conditions to achieve the temperature gradient and growth rate necessary for formation of the Al₆ Fe compound as defined by the area to the right of the boundary line A--B in the diagram in FIG. 4. However, in practical situations either in the production of castings by conventional processes, or when casting shapes for subsequent mechanical working by the semi-continuous process, it may not always be possible to achieve the growth rate/temperature gradients required for the formation of the Al₆ Fe structure throughout the complete cross-section. Another important preferred aspect of the invention, therefore, is the addition of alloying elements in trace quantities (0.005 - 0.10%) to achieve -

a. a refinement of the Al₃ Fe structure and/or

b. an effective displacement of the boundary delineating the two structures to conditions of lower temperature gradients and lower growth rates (i.e. effective movement of the boundary to the left and downwards in FIG. 4) thereby enabling the formation of the desired Al₆ Fe structure under conditions encountered in practical casting situations.

Thus, a refined structure containing the Al₆ Fe compound or a refinement (i.e., to a particle size less than 10 microns) of the Al₃ Fe compound can be produced by addition to the alloy of one or more of the elements, lithium, sodium, strontium, barium, in individual amounts of 0.005 to 0.10%, the total addition not exceeding 0.4%, in conjunction with solidification under the appropriate temperature gradient and growth rate conditions.

The effect of each alloying element enumerated above is dependent upon the combination of conditions of temperature gradient, growth rate and percentage addition. For example it is found that at very low temperature gradients and growth rates, it is possible to refine the Al₃ Fe compound by the addition to the alloy of e.g. 0.12% lithium (see FIG. 5) or 0.05% sodium (see FIG. 6), whereas strontium additions to 0.05% have no effect until the temperature gradient is increased to greater than 30 degrees C/millimeter, when the Al₆ Fe structure can be formed (see FIG. 7).

The invention accordingly provides aluminum base alloys containing 0.5% to 10% Fe and the usual impurities, which may include Mg, Mn, Si, Cu, Ti, up to a total maximum of 0.5%. In a preferred form the alloys may also contain one or more elements selected from the group consisting of lithium, sodium, strontium and barium in the range 0.005 to .10% of each, the total addition not to exceed 0.4.

The invention also provides a heat-treatment of the alloy so as to produce a ductile structure suitable for ease of mechanical working treatments.

The abovementioned alloying elements may be added to the molten alloy either prior to, or subsequent to the addition of iron to the molten aluminium, and may be added either as the element or in the form of a hardener, or reacted with molten aluminium as a flux to achieve the addition by chemical reaction.

By way of actual example the mechanical properties in the (i) as cast and (ii) cold worked condition of a typical aluminium-iron alloy (2.5% Fe) possessing the Al-Al₆ Fe structure are shown in Table 1. The actual structure of the alloy is shown in FIG. 8. This alloy did not contain any of the above-specified alloying elements.

                  TABLE 1                                                          ______________________________________                                                                U.T.S.                                                                         (Ultimate)                                                         0.1%        Tensile                                                            Proof Stress                                                                               Strength    %                                           Condition  (lbs/sq.in) (lbs/sq.in) Elongation                                  ______________________________________                                                    48,510      62,515      2.7                                         As cast    36,414      77,285      0.4                                         (growth rate                                                                              32,720      63,150      2.6                                         R = 2500   55,510      78,175      0.4                                         microns/sec,                                                                              44,050      64,680      2.1                                         temperature                                                                    G = 10° C/mm                                                            Above cold 48,510      55,510      8                                           worked     43,930      56,022      7                                           (94% Reduc-                                                                               49,780      55,000      8                                           tion of    51,660      56,150      7                                           Area)                                                                          ______________________________________                                    

It will be seen that as a result of possessing the Al-Al₆ Fe structure which was produced by controlling the growth rate R during casting and solidification, using a directional solidification furnace, excellent strength, stiffness and elongation values are obtained in the above alloy.

For a comparison a typical range of as cast mechanical properties of a similar alloy containing 2.5% Fe, but prepared in such a way that the values of R and G required to form the Al₆ Fe structure are not attained, are shown in Table 2. This alloy contains an unrefined Al₃ Fe structure, and is a brittle and much weaker alloy. It contains large particles or long interconnected plates of the Al₃ Fe compound, and cannot be cold worked satisfactorily (see also FIG. 2).

    ______________________________________                                         0.1% Proof Stress                                                                           U.T.S.        %                                                   (lbs/sq.in)  (lbs/sq.in)   Elongation                                          ______________________________________                                          9,600 - 15,000                                                                             15,000 - 30,000                                                                              1 - 3                                               ______________________________________                                    

It has been stated earlier in this specification that the addition of one or more of the elements Li, Na, Sr, Ba, in amounts ranging from 0.005 -0.10% with the total not exceeding 0.4% (see also FIGS. 5, 6 and 7) enables refinement of the Al-Fe structures of aluminium-iron alloys and consequent improvements in mechanical properties, particularly in ductility. Typical results obtained are shown in Table 3 below:

                  TABLE 3                                                          ______________________________________                                                    0.2%         U.T.S.                                                            Proof Stress (lbs/     %                                            Alloy      (lbs/sq.in)  sq.in)    Elongation                                   ______________________________________                                         Aluminium- 6,500        12,000    2.8                                          2.8% Fe                                                                        Aluminium- 8,300        16,200    10.5                                         2.8% Fe                                                                        0.06% Sr                                                                       ______________________________________                                    

The growth rate R is both the above alloys was the same, 100 microns/minute.

Another advantage of the alloys of this invention possessing the preferred microstructures herein described, is that their ductility in the as cast condition can be very significantly improved by prolonged thermal treatments at temperatures just below the eutectic temperatures followed by air cooling or water quenching. This is clearly indicated in the results presented in Table 4.

                  TABLE 4                                                          ______________________________________                                                        0.2%                                                                           Proof                 %                                                        Stress    U.T.S.      Elong-                                    Alloy          (lbs/sq.in)                                                                              (lbs/sq.in) ation                                     ______________________________________                                         (A) Aluminium- 8,300     16,200        10.5                                    2.8% Fe, 0.06%                                                                 Sr, as cast.                                                                   (A) after holding                                                              at 600° C for:                                                          8 hours        6,700     14,700      17                                        16 hours       6,450     15,100      19                                        24 hours       6,400     14,700      20                                        (B) Aluminium-2.6%                                                             Fe, as cast,(6 7/16"                                                           diameter billet in       20,000-23,000                                                                              10-15                                     direct chill mould).                                                           (B) after holding at                                                                          Not                                                             600° C for 8 - 24 15,000-16,000                                                                              23-26                                     hours and air cooling                                                                         Determined                                                      (B) after holding at                                                           600° C for 24 hours                                                                              15,300-15,600                                                                              21-25                                     and cold water                                                                 quenching.                                                                     ______________________________________                                    

Some typical hardness values of an alloy containing 2.6% Fe before and after exposure to 600° C, respectively, slowly cooled and quenched are given below:

                  TABLE 5                                                          ______________________________________                                                             Typical                                                                        Vickers Hardness No.                                       Alloy               (10 gram load)                                             ______________________________________                                         Aluminium - 2.6% Fe,                                                           as cast in form of  58                                                         6 7/16" diameter billet,                                                       with Al.sub.6 Fe                                                               As above, heated to 600° C                                              for 8 to 24 hours,  46                                                         slow cool.                                                                     As above, heated to 600° C                                              for 24 hours,       30                                                         cold water quench.                                                             ______________________________________                                    

The corrosion resistance of the alloys of this invention is roughly comparable with that of aluminium alloys in the 6000 series. 

We claim:
 1. In a method of casting aluminum-iron alloy from a melt with a controlled temperature gradient between the solid and liquid metal and with a controlled rate of growth of the alloy phases as they solidify, said alloy consisting essentially of aluminum and 0.5 to 10% by weight of iron and having a cast microstructure containing aluminum and eutectic compounds including Al₃ Fe and Al₆ Fe and mixtures thereof, the improvement which comprises providing in said melt at least one constituent from the group consisting of lithium, sodium, strontium or barium in an amount which is effective to improve the strength or ductility of said alloy by producing in said alloy a refined form of Al₃ Fe or very fine Al₆ Fe, the amount of each constituent being up to 0.1% by weight of said melt and the total amount of such constituents not exceeding 0.4% by weight of said melt.
 2. Method according to claim 1 wherein the temperature gradient and growth rate during casting are controlled at values to the right of boundary line A-B of FIG. 4 hereof.
 3. Method according to claim 1 wherein the resultant alloy is subjected to prolonged thermal treatment just below the eutectic temperature for more than 8 hours, followed by air cooling or water quenching, whereby improved ductility is obtained.
 4. The cast product produced by the method of claim
 1. 5. The cast product produced by the method of claim
 2. 6. The cast product produced by the method of claim
 3. 